Documented engagement results from container glass plants worldwide.
Anonymised by NDA. Verifiable on request. Numbers are real, plants are not named, methodology is open.
European spirits plant — 47% job change time reduction
Baseline average changeover time of 14h 20min. Cross-shift variance of 38%. First-hour yield (saleable / produced in first 60 minutes after restart) at 62%. Sales had three large-volume SKU contracts up for renegotiation that hinged on lead-time commitments the plant couldn't reliably make. The CEO had received quotes from two OEM-tied consultancies; both proposals included substantial equipment recommendations.
LATAM beer plant — 6 OEE points + 80% cross-shift variance collapse
Baseline OEE of 72%. Cross-shift variance on Line 3 (the highest-volume line) of 18 percentage points between best and worst shift. Pack-to-melt at 81%. Persistent settle-wave defect mode that the forming team had been chasing for 9 months without resolution. The plant had been told by an OEM-tied consultancy that the path forward was a $4.2M mould-cooling capex programme.
South Asian pharma container plant — first-ware quality 78% → 96%
First-ware quality on the SKU 14-mix averaged 78% — far below the 95%+ regulatory expectation under cGMP. Persistent customer rejections on dimensional defects in the first hour after each changeover. The plant had committed to a regulatory remediation plan with the customer; the next quarterly customer audit was 8 weeks away.
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